robust, reliable ac drives for significant capex and opex...

Robust, reliable AC drives for significant CAPEX and OPEX savings in mining and mineral processing

Mining and minerals

85% lessswitchroom heat load is achievable using high-effi ciency AC drives equipped with innovative back-channel cooling.

drives.mining.danfoss.com

Save costs with VLT® and VACON® drives

Did you know that certain AC drives are designed for exactly the needs of mining and mineral processing plants, coping with extreme conditions, heavy loading and controlling equipment installed a long distance away?

When using VLT® and VACON® drives, often you can even save on the cost of other equipment.

2 Danfoss Drives · DKDD.PB.423.A2.02

3Danfoss Drives · DKDD.PB.423.A2.02

Expertise – the benefi t of an experienced partnerWant a partner who understands your

issues in depth? And who can give

you the winning edge? With the most

dedicated mining drive solutions and

expertise on offer, Danfoss Drives

can be that valuable partner, helping

you to create competitive solutions.

We ensure the optimum selection of

products to fulfill all your mining and

processing equipment application

requirements. By optimizing AC drive

applications we can provide solutions

that significantly reduce initial project

and ongoing operating costs..

Whatever low voltage AC drive you

require, we can deliver it, on time, no

matter where you are located. VLT® and

VACON® drives operate reliably over

decades of use in harsh environments

saving maintenance costs, ensuring

better asset availability and providing

you with the lowest cost of ownership.

All our drives integrate seamlessly into

all common PLC fieldbus networks.

VLT® and VACON® drives are fully

compatible with all AC motor makes

and types. We ensure drive and

motor compatibility on long cable

installations, regardless of which

motor supplier has been chosen, and

mains supply compatibility through

harmonics calculations, reports and

mitigation solutions.

No matter how well you have optimized your plant design, there is always a way to drive down costs even further. AC drives are used extensively for just that purpose, extending equipment lifetime, optimizing processes, reducing maintenance and saving energy costs.

The mining and minerals industry presents some of the most challenging environments for production. Mine sites, mineral processing facilities and associated stockyards and port facilities are large scale and often in remote locations.


Standard design for long cables saves initial project costs The large-scale layout of mine processing plants and

port facilities often results in cable lengths between

AC drives and motors being long, relative to other

industries. Cable lengths are typically 50 m to 150 m,

and sometimes more.

These relatively long cable lengths can put electrical

and thermal stress on the internal components of a

drive if it is not designed for the purpose, resulting in

unreliable operation or even failure of the AC drive.

Contractors and end users alike have learnt that

selecting a drive that is designed as standard to be

installed with the length and type of cable required for

the installation, helps to save initial project costs.

When this drive also complies with international

EMC standards for installations with long motor

cables, you can

Ensure long-term, reliable operation

Minimize the risk of affecting operation of other

electrical equipment installed on site

Save purchase and installation costs of external

filters

Read more on page 10.

Signifi cant cost-saving opportunities, both in CAPEX and OPEXDid you know that compact AC drives with intelligent

heat management can deliver surprisingly significant

savings to your mine site operations?

Initial CAPEX savings opportunities

Compact enclosures often mean switchrooms can

be designed and built smaller

The back-channel cooling design of higher power

drives results in significantly lower heat loads in

switchrooms, enabling the purchase of a smaller,

lower-cost air-conditioning system

Long-term OPEX savings opportunities

The energy-efficient design of VLT® and VACON®

drives ensures that they comply with the strictest

requirements of the European standard defining

efficiency classes for “power drive systems and

motor starters”, EN 50598-2, and both are classified

as IE2. The IE2 classification means that when

you use VLT® and VACON® drives to control your

equipment, you’re using AC drives that meet the

highest benchmark for efficiency, minimized losses

and lower operating costs

Use of a smaller air-conditioning system results in

lower operating costs

Read more on page 8.

Kolomela Mine


Local service

Once installed, Danfoss drives are backed up by our local service and support teams, manned by dedicated drive specialists with proven mine site application and installation experience. The DrivePro® range of services caters to your every need.

Wherever you are, you can rely on us. With more than 100 sites world-wide, we are never far away, however remote your mine site is. With over 18 million drives produced since 1968, we’re a solid company you can trust to deliver.

How we add value for you

Make the most of Danfoss Drives’ application and engineering support to optimize your mining project right from the initial feasibility study stage through to the detailed design, execution and operation stages.


Provenexperience in all mine processing and bulk material handling facilities

On many mining projects across the

globe this support has helped mining

companies, consultants; engineering

service providers and contractors

design robust, reliable, energy-efficient

drive solutions. These have resulted

in significant initial project cost and

ongoing operating cost savings.

Reap the benefits of our specialized

support services, based on decades

of extensive experience. Our design

skills include ensuring:

Drive and motor compatibility on

long cable installations, regardless of

which motor supplier is preferred

Mains supply compatibility through

harmonics calculations, reports and

mitigation solutions

Mining companies around the globe

have reduced costs and improved

reliability. See more on page 16.

No matter what your needs are, we meet them

For mining applications, Danfoss Drives delivers the full package of proven experience, local availability for application design and service, and unequalled product quality.

Gain from Danfoss’ proven experience in AC-drive technologies for mining

applications. VLT® and VACON® drives have been installed and operating

reliably for many years on mine sites, stockyards, bulk materials handling

facilities, processing plants and related port facilities – experience used to

optimize drive design.

At Danfoss we can supply absolutely any low voltage AC drive you need,

for the mine or processing plant – or for equipment OEMs delivering to the

industry.

We offer the full range no matter what your requirements:

You choose whether to incorporate the drives into a panel, switchboard

or Motor Control Center (MCC); install directly on the wall or floor of your

switchroom or substation; integrate air or liquid cooled drive modules

into your mining equipment; or even install outside with suitable, simple

sheltering from the elements

Motor-independent drives, fully compatible with all AC motor makes

and types

Drives which are PLC-network independent and easy to integrate into

networks, no matter which PLC you prefer

You can also rely on our quality. VLT® and VACON® drives are mass-

customized, factory assembled and fully factory tested.

Danfoss Drives · DKDD.PB.423.A2.02 7

Why choose Danfoss drives for mine and mineral processing environments?

With our wide range of AC drives and a broad choice of supporting options we can match your specifi c requirements. The compact enclosures and robust design of our drives with built-in long motor cable capability, innovative heat management and other mine-site-relevant features can help you optimize your panel, switchboard, switchroom or substation design, saving costs and improving your competitive position.

Intelligent heat management for signifi cantly lower switchroom costsWith the increasing use of AC drives

to efficiently control equipment

on mine sites, the heat loads in

switchrooms from those drives are

demanding larger and more expensive

air-conditioning systems. However,

the unique back-channel cooling

design of higher power VLT® drives

and availability of VACON® liquid-

cooled drives can result in significantly

reduced heat loads in switchrooms,

enabling the use of smaller, lower-cost

air-conditioning systems.

VLT® drives rated 90 kW and higher

incorporate an innovative back-

channel cooling design. There

are separate cooling paths for the

power components and control

electronics, separated by an IP54 seal.

The back-channel cooling removes

approximately 85% of the power

loss directly through the heatsink,

leaving only 15% of the total loss

to be dissipated in the switchroom.

Although separate cooling paths

themselves are not innovative, the

innovation in our VLT® drives comes

from ensuring they are separated by

an IP54 seal and making it easy to duct

outside air into and out of the back-

channel air path.

Reduced heat load

in switchrooms

When outside air quality on the mine

site is suitable, using the heatsink

cooling fans and appropriate mounting

and ducting, filtered external air at

temperatures up to 50 degrees C can

be used to exhaust approximately 85%

of the heat loss from the VLT® drive.

The heat loss can easily be exhausted

directly outside the switchroom

with no effect on the switchroom

pressurization. The switchroom air-

conditioning system only needs to be

sized for the remaining 15% heat losses

into the switchroom.

Compact enclosures

reduce project costs

The compact size of VLT® and VACON®

drives, both designed as standard for

long motor cables without requiring

additional options, often means

smaller switchrooms can be built,

providing opportunities for significant

switchroom cost savings.

Ask us, to find out how contractors

and mining companies have saved

significant project and operating costs

through the use of these innovative

design features.


High-temperature reliabilityDanfoss VLT® and VACON® drives are

designed as standard to operate in

high ambient temperature conditions

without de-rating and compared to

many other drives, to be installed in

environments containing relatively

high levels of contaminants. Through

the most innovative internal cooling

systems available, they also ensure

their internal components are cooled

efficiently and effectively whilst

minimizing the air flow across the

sensitive, small electronic components

mounted on the printed circuit boards

inside. This, combined with their

standard design enabling them to

operate reliably even when installed

with long cables between the drive

and motor, makes them an optimum

choice for mine site installations.

Designed for harsh environmentsRobust design, inclusion of harmonic

and radio frequency interference

(RFI) filters and ability to be installed

with long motor cables are standard

features for all VLT® and VACON® drives.

Harsh, dusty conditions and extreme

temperatures are common and can

create challenges for any electronic

product. Although it is increasingly

common practice on modern mine

sites to install drives in relatively

clean, pressurized, air-conditioned

switchrooms and substations, it has

become well-recognized that a drive

designed for harsh environments will

have a significantly longer, trouble-

free lifetime. This ultimately ensures

better asset availability and saves

maintenance costs for the mining

company.

VLT® and VACON® drives are developed

to meet the vast majority of mining

and processing equipment application

and installation requirements with

no need for tailored solutions. Their

reliability in the typical arduous

environments found on mine sites is

proven over many years’ service.

VLT® and VACON® drives incorporate:

Electronics coating protection that

ensures the drives are suitable

for installation in mine-site

environments

No external forced draft cooling

across internal components, for

IP54/55 versions of lower power

drives. External cooling air from the

temperature-controlled cooling fans

is blown across the external heatsink

and not through the internal

electronics of the drive

Back-channel cooling for VLT®

high-power drives. This greatly

reduces contamination of the

control electronics area, resulting in

longer life and higher reliability. The

remaining heat losses are removed

from the control electronics area

using door fans and, because

these heat losses are relatively low,

only a low volume of air needs

to be blown through the control

electronics area

Long motor cable capability as standard Without the need for additional

components, standard VLT® or VACON®

drives provide trouble-free operation

with cable lengths of up to at least

150 m for screened cables and 300 m

for unscreened cables.

No additional output filters are

required for the drive to reliably

operate with these cable lengths. This

saves space and installation time and

costs compared to traditional AC drive

solutions.

With the built-in RFI filters, VLT® and

VACON® drives comply with EMC

standards, ensuring reliable operation

of all other electrical equipment on

the same installation. No additional RFI

filters are required on the input of the

drive.

Being designed for long motor cable

installations as standard typically

results in a more compact solution

compared to AC drives that need to

add options to operate reliably with

long motor cables. This often results in

considerable initial project cost savings

as a result of being able to use smaller

switchrooms.

Even for motor cables up to 150 m long, VLT® drives comply with EMC standards

Why choose Danfoss drives for mine and mineral processing environments?


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Danfoss Drives · DKDD.PB.423.A2.0212

Applications

1 Long conveyors2 Stockpile reclaim feeders3 Borehole pumps4 Stacker/reclaimer5 Conveyors6 Ship loader7 Dewatering pump skids8 Thickeners (pinion drives, feed,

overflow and underflow (slurry)

pumps)9 Ball mills; flotation cells; apron

feeders, conveyors, slurry pumps

(e.g. transfer pumps, feed pumps,

concentrate pumps, tailings

pumps); process water pumps 10 Train unloader11 Excavator12 Tripper car13 Train loadout conveyor14 Slurry pumps; process water feed

pumps; dosing pumps; filters15 Primary ventilation fans16 Underground conveyors17 Booster fans18 Crusher19 Slurry pumps (e.g. cyclone feed

pumps; transfer pumps; thickener

underflow pumps); feeders;

screens20 Stacker21 River water pumps

22 Underground mines

Mine ventilation fans

Conveyors

Pumps

Winders

5

5

11

12

1

13

14

16

17

18

19

20

21

22


Long conveyor capability

Smoothly controlling the acceleration

and deceleration of long conveyors

reduces mechanical stress through all

drive-train components and within

the conveyor belt itself. This leads to

longer lifetime for the belt and other

drive components, increasing asset

availability and lowering maintenance

and operating costs. Having the

flexibility to control the speed of long

conveyors can help optimize the

complete system, reduce bottlenecks

and maximize the efficiency of a

material flow process, resulting in

operating cost savings.

Maximize belt lifeIt’s common practice to install multiple

motors on long conveyors and the

drives need to ensure load sharing

between each motor for reliable

operation and to maximize belt life.

VLT® and VACON® drives include both

Master-Master and Master-Follower

control solutions for this. Selection of

the control solution depends on the

configuration of the conveyor drives

on the conveyor (for example, all drives

at the head end or drives at both the

head and tail end).

They are both easy to implement and

have proven to be robust, reliable

solutions for long conveyors.

Bulk handlingFor downhill conveyors, where

continuous regenerative braking

operation is typically required, an

Active Front End (AFE) drive or

alternatively a regenerative drive panel

solution, using a standard 6-pulse drive

with separate regenerative module, is

the best solution.

VLT® and VACON® drives are used

extensively on many long conveyors

in excess of 1-km length, which are

common on bulk material applications

on mine sites, processing plants and

port facilities such as:.

Run-of-mine (ROM) bin feeder

conveyors

Stockyards

Train loadout conveyors

Pipe conveyors

Long overland conveyors

Ensuring reliable ventilation of the

mine is paramount for the health and

safety of workers in the underground

mine. This is necessary to ensure

particulates from diesel engines are

adequately diluted, for example.

Ventilation operating costs are often

a significant proportion of the total

electrical energy costs on site, and

being able to ventilate in the most

efficient manner saves significant

operating costs.

Robust mine ventilation

AC drives are well recognized to be the

most flexible, energy-efficient, low-

maintenance method for controlling

mine ventilation fans. They are

used to control the air flow of main

ventilation fans on the surface as well

as auxiliary ventilation and booster

fans underground, and can be easily

integrated into Ventilation on Demand

(VOD) control systems.

Both VLT® and VACON® drives

incorporate a number of features that

make them especially suitable for mine

ventilation fan applications. These

ensure reliable operation of the fan

even in abnormal operating conditions

and the optimum use of energy


Slurry pumps are used extensively

throughout many processing facilities,

and AC drives are often used to control

them. The AC drives provide flexibility

in control and optimize yields from

equipment, and therefore enhance

the overall efficiency of the plant. For

example, use of a drive to control

the flow of feed pumps to a dense

medium cyclone on a coal handling

and preparation plant (CHPP) helps

deliver greater yield.

A slurry pump is typically a centrifugal

pump and for many applications,

under normal operating conditions,

AC drives will operate reliably if they

have been selected based on what

is typically referred to as a normal

overload or normal duty rating.

However, normal operating conditions

do not always prevail on a mine site.

Mains supply interruptions or

emergency stop conditions which

cause equipment to stop in an

uncontrolled manner can result in

slurry pumps and pipelines being

full of the slurry when the pump

stops

If the slurry is particularly dense,

and the duration of downtime is

long, the dense material in the

slurry settles to the bottom of the

pump and pipeline, often making it

difficult to restart.

For environmental and lower

maintenance and operating cost

reasons, many mine sites prefer to use

an electric-driven pump skid instead

of the traditional diesel-engine-driven

pump skid. This is possible when there

is an electrical supply close to the

dewatering pump skid location.

An electric driven pump skid typically

uses an AC motor and drive to set the

flow rate of the dewatering pump

instead of a diesel engine. Typically

the initial cost of an electric-driven

skid will be higher, but the operating

costs are significantly lower. The higher

initial investment is recovered very

quickly, often within months. As there

is no need to change the oil of a diesel

engine every few hundred operating

hours, or pay for refueling trucks and

labor, this results in even greater

savings in maintenance and operating

costs.

Common challenges for drives on

electric-driven pump skids include

the space available (because the size

of the drive often impacts the size

and therefore cost of the pump skid)

and the harsh, dusty and often hot

environment where the pump skid is

installed.

VLT® and VACON® drives address these

challenges with ease and are used

extensively on dewatering pump skids

on many mine sites. Their compact

enclosures often enable the pump

skid manufacturer to minimize the size

and cost of the skid. Their robust, high

ambient temperature design ensures

reliable, long lifetime of operation

even when installed on a dewatering

pump skid out in the open, on a hot,

The optimum choice for electric-driven dewatering pump skids

Reliable operation of slurry pumps throughout your processing facility

humid mine site with mining trucks

kicking up dust as they pass by every

few minutes. IP66 enclosures for a

wide power range make it easy to

install them on the pump skid, with

a simple weather shield to provide

shading. For higher power sizes, the

back-channel cooling design of the

VLT® drives often means that for many

mine sites, even in hot climates, they

can be installed on the pump skid in

a simple weather-proofing enclosure

without any additional cooling fans

or air-conditioning system, ensuring

a robust, reliable, low-maintenance

solution.

For such situations, best practice

in selecting AC drives for slurry

pumps is to select them based

on an overload rating that at least

ensures 150% motor torque for 30

seconds. All VLT® and VACON® drives

are suitably rated to ensure reliable

operation of all slurry pumps

throughout your facility


30% energy reduction for Yamana Gold in Bahia, BrazilVACON® AC drives improve the

operation of underground ventilation

and pumping systems and cut energy

consumption of many application

processes.

Optimized production at KWB Coal Mine, Konin, Poland90 kW VLT® Drives ease the mechanical

stress on the heavy equipment and

improve steering when the excavator

turns sideways.

80 kW power savings at Kolomela mine, South AfricaBack-channel cooling in VLT®

AutomationDrives reduces substation

heat load enabling use of a smaller air-

conditioning system with lower power

consumption.

Minimal energy use at Shanxi Zhongxi Cement. Xiaan Province, China VLT® Drives move a 10.5-km-long

conveyor belt. Load sharing between

drives and the use of regenerative

modules transfers energy from

downhill segments to the uphill parts.

75% cost reduction in mining barge at Kovin, SerbiaReplacing the barge’s diesel engine

with an electrical motor controlled

by a VLT® AutomationDrive increased

reliability and reduced costs.

Other referencesFirst Quantum Minerals Ltd sites

– Kansanshi Copper, Zambia

– Kevitsa Mine, Finland

– Guelb Moghrein, Mauritania

Energy Resources of Australia

Ranger Uranium site, Australia.

Alcoa of Australia bauxite mines

and alumina refineries.

St. Barbara Limited

– Simberi Operations, Solomon Islands

Heathgate Resources

– Beverley Uranium Mine,

South Australia

References


Products

Robust, reliable AC drives for mining and mineral processingVLT® and VACON® drives are available for all low voltage mains sup-plies, from fractional kW to more than 2 MW for all mining and mineral processing equipment applications. They are available as standard in a wide range of wall-mounted and fl oor-standing, IP and NEMA/UL-type-rated enclosures to meet your specifi c installation needs, and air-cooled and liquid-cooled modules for integrating into your mining equipment. Regenerative drives for regenerative applications and a wide range of harmonic mitigation products provide you with an opti-mum solution that meets your requirements.

IntegratedBAC BACnet

META Metasys N2

MOD Modbus RTU

TCP Modbus TCP

BIP BACnet/IP

OptionalPB PROFIBUS DP V1

PN PROFINET

PL Powerlink

DN DeviceNet

CAN CANopen

AKD LONworks for AKD

LON LONworks

BAC BACnet (MSTP)

TCP Modbus TCP

EIP EtherNet/IP

ECAT EtherCAT

DCP DCP 3/4

DSP CANopen DSP 417

BIP BACnet/IP

Communications functionality This legend indicates the communication interface and

fi eldbus protocol functionality which is specifi c to each

product. For details, please refer to the individual

product brochures.


The VLT® Soft Starter MCD 500 is

the comprehensive solution for soft

starting and stopping three-phase

induction motors. Integrated

current transducers measure the

motor current and provide important

data for optimal start and stop

ramps. A built-in bypass is available

up to 961 A.

Adaptive Acceleration Control (AAC),

adjusted to the respective load,

ensures the best possible start and

stop ramps in order to avoid water

hammering.

Integrated monitoring functions

provide comprehensive protection,

including: phase error detection, thy-

ristor monitoring and bypass contact

overload.

Technical data

Input ............................................ 3 x 200-690 V

Control voltage ............................. 24 V DC or

............................................................110-240 V AC

Power ..............7.5-850 /2400* (1600A) kW

*”Inside delta connection”

VLT® Soft Starter MCD 500

Protection ratingIP00 IP20 IP21/Type 1

IP54/Type 12 IP55/Type 12 IP66/Type 4X

Fieldbus

DN PB MOD

VLT® drives

The VLT® AutomationDrive FC 302, VLT® AQUA Drive FC 202 and VLT® HVAC Drive FC 102 are all built on the same modular platform, allowing for highly-customized drives that are mass-produced, fully-tested, and delivered from our factories. As standard they are designed to operate reliably with up to at least 150 m

screened or 300 m unscreened cable lengths, with no need for additional output

fi lters. They include a built-in DC link choke harmonic fi lter and can be confi gured

with built-in RFI fi lters, providing diff erent levels of EMC performance as required.

Compliance with the most commonly specifi ed international EMC standard for

mining and mineral processing facilities, IEC 61800-3 Category C3, with 150 m

screened cable, is standard.

Their robust design ensures that as standard they are suitable for installation in

harsh environments as defi ned by IEC 60721-3-3 Class 3C2 and are available with

an optional, higher grade PCB coating, making them suitable for installation in

even harsher, Class 3C3, environments of that standard. With only a few excep-

tions, all drive sizes are designed for operation at their full nominal current ratings

in ambient temperatures up to 50 0C (high overload) and 45 0C (normal overload)

without derating.

The back-channel cooling feature for powers ≥90 kW (high overload) / 110 kW

(normal overload) has proven to save signifi cant initial and ongoing operating

costs on mining projects across the globe.

Additional harmonic mitigation

12-pulse versions or low harmonic drive versions, incorporating a parallel-connect-

ed advanced active fi lter (AAF) in the same enclosure as the drive, are available

as well as standalone AAFs for central compensation of harmonics and passive

Advanced Harmonic Filters (AHF) for installation on the input of a drive.


VLT® AutomationDrive FC 302Used extensively for all mining and

mineral processing equipment appli-

cations and on stockyards and bulk

material handling facilities, VLT® Auto-

mationDrive FC 302 ensures optimal

operation of all equipment, including

conveyors, feeders, crushers, mills,

screens, slurry pumps, fl otation cells,

paste thickeners, ship loaders, stackers,

reclaimers, and more.

All kW ratings below are based on

high overload ratings.

Power range

3 x 200-240 V ..................................0.25-37 kW

3 x 380-500 V ...............................0.37-800 kW

3 x 525-600 V ..................................0.75-75 kW

3 x 525-690 V ................................1.1-1200 kW

Power range - Low harmonic drive

3 x 380-480 V ......................... ......132-630 kW

Power range - 12-pulse drive

3 x 380-500 V...................... ..........250-800 kW

3 x 525-690 V ...................... ...... 250-1200 kW

VLT® AQUA Drive FC 202Used on mine sites and mineral pro-

cessing plants, VLT® AQUA Drive con-

trols all types of pumps, including cen-

trifugal pumps (with quadratic loads)

and displacement and screw pumps

(with constant torque load). On mine

sites VLT® AQUA Drive is commonly

used for mine de-watering pumps and

borehole pump applications, often in-

stalled outdoors on pump skids or next

to borehole pumps, with appropriate

enclosures providing protection from

the weather and shading from the sun.

Pump protection functions are built in

and the Automatic Energy Optimiza-

tion function ensures the motor, not

only the pump, is operating at its best

effi ciency point.


normal overload ratings.

Power range

3 x 200-240 V .................................0.25-45 kW

3 x 380-480 V .............................0.37-1000 kW

3 x 525-600 V ................................. 0.75-90 kW

3 x 525-690 V ................................1.1-1400 kW


3 x 380-480 V ......................... ...... 160-710 kW


3 x 380-500 V....................... ........315-1000 kW

3 x 525-690 V ...................... ......450-1400 kW

Protection rating

IP00 IP20 IP21/Type 1


Protection rating



Used to control the air fl ow of main

ventilation fans on the surface as well

as auxiliary ventilation and booster fans

underground, VLT® HVAC Drive can be

easily integrated into Ventilation on

Demand (VOD) control systems. Built-in

functions ensure reliable, continued

operation of the fan even in abnormal

operating conditions. The Automatic

Energy Optimization function improves

the overall effi ciency of the drive

and motor combined at all loads and

speeds, resulting in lower operating

costs and the optimum use of ener-

gy. Effi ciency gains of >0.5% for the

total system (switchroom + AC drive +

motor + fan) are common compared

to other “standard” AC drives. And as

main ventilation fans are high energy

users, an improvement in total effi cien-

cy of just 0.5% translates to signifi cant

operating cost savings.


normal overload ratings.

Power range

3 x 200-240 V ....................................1.1-45 kW

3 x 380-480 V ...............................1.1-1000 kW

3 x 525-600 V ....................................1.1-90 kW

3 x 525-690 V ...............................1.1-1400 kW


3 x 380-480 V ......................... .....160-710 kW


3 x 380-500 V...................... ........315-1000 kW

3 x 525-690 V ...................... .....450-1400 kW

VLT® HVAC Drive FC 102

Protection ratingIP00 IP20 IP21/Type 1


Fieldbus

MOD

DN CAN PB TCP EIP

ECAT PN PL

Fieldbus

MOD

PN DN PB TCP EIP

Fieldbus

MOD META BAC

DN LON BAC TCP EIP

PB PN BIP


VACON® drives

The broad range of VACON® NXP drives provides solutions no matter what type of AC drive you need. Air cooled or liquid cooled, wall mounted or fl oor standing, bottom or top cable entry, 6-pulse, 12-pulse or Active Front End (AFE) are just some of the options possible.

As standard they are designed to operate reliably with up to 300m cable lengths (power size dependent), without the need for any additional output fi lters. They include an AC choke harmonic fi lter and can be confi gured with built in RFI fi lters providing diff erent levels of EMC performance as required, including compliance with the most commonly specifi ed international EMC standard for mining and mineral processing facilities, IEC 61800-3 Category C3.

Active Front End (AFE) versions of the VACON® NXC and AFE modules combined with separate Inverter Unit (INU) modules provide solutions for regenerative appli-cations and when low harmonic current distortion is required.

The VACON® 100 INDUSTRIAL drives are designed to operate reliably with up to 200m cable lengths (power size dependent), include a built in DC link choke harmonic fi lter and include a built in RFI fi lter ensuring compliance with at least IEC 61800-3 Category C3.The built in PLC functionality according to IEC61131-3 of both the VACON® NXP and VACON® 100 enables OEMs to integrate their own functionality in the drives.


VACON® NXP andVACON® NXC Air CooledUsed extensively for all mining and

mineral processing equipment appli-

cations and on stockyards and bulk

material handling facilities including

conveyors, feeders, crushers, mills,

screens, slurry pumps, fl otation cells,

paste thickeners, ship loaders, stackers,

reclaimers, mine ventilation fans, dewa-

tering pumps, and more.



Power range

3 x 208-240 V ................................... 0.37-75 kW

3 x 380-500 V .............................0.75-1100 kW

3 x 525-690 V ...............................2.2-1800 kW


3 x 380-500 V ..............................110-1200 kW

3 x 525-690 V ................................90-1800 kW


3 x 380-500 V...................... .........160-1100 kW

3 x 525-690 V ...................... ......200-1800 kW

VACON® NXP IP00 drive modulesThese compact drive modules with

separate AC chokes and separate front

end and inverter unit modules for

higher powers are ideally suited for

applications where drives need to be

built into low height enclosures as is

often common on underground coal

mine motor starter skids.

Complemented by a comprehensive

range of air cooled VACON® NXP com-

mon DC bus modules and VACON®

NXP liquid cooled drives and modules,

there really isn’t a tight space or harsh

environment where we can’t provide

you an AC drive that meets your needs.



Power range

3 x 380-500 V ..............................160-1100 kW

3 x 525-690 V .............................200-1800 kW

Protection rating



Protection rating



Protection rating


*


*

The VACON® 100 INDUSTRIAL is a

workhorse for a wide range of indus-

trial applications. It is easy to integrate

into all major control systems and is

easily adaptable to diff erent needs. All

power sizes are available as drive mod-

ules. The free-standing enclosed drive

version for higher power sizes contains

a wide range of confi gurable options

and an innovative control compart-

ment for safe access, without opening

the cabinet door.



Power range

3 x 208-240 V ................................... 0.37-75 kW

3 x 380-500 V ...............................0.75-500 kW

3 x 525-690 V .....................................4-630 kW

VACON® 100 INDUSTRIAL

Fieldbus

MOD META

DN CAN PB TCP EIP

BAC PN LON

Fieldbus

MOD META

DN CAN PB TCP EIP

BAC PN LON

*Dependent upon enclosure size

Fieldbus

MOD META BAC TCP BIP

PB DN CAN BAC LON

TCP EIP PN ECAT


While AC drives help optimize production, save energy and extend equipment lifetime, they also introduce harmonic currents to the mine-site grid.

If not kept under control, these harmonics can aff ect the performance and reliability of generators and other equipment.

Harmonics mitigation

Harmonics mitigation solutions

Adverse effects of harmonics

Limitations on supply

and network utilization

Increased transformer,

motor and cable heating

Reduced equipment lifetime

Costly equipment downtime

Control system malfunctions

Pulsating and

reduced motor torque

Audible noise

Reliable estimation of the harmonic

impact of AC drives on the mine site

electrical system, combined with

the use of the optimum mitigation

equipment, helps plants avoid

the hidden and often expensive

consequences of harmonic distortion.

All VLT® and VACON® drives supplied

for mine site installations incorporate

a DC link choke or AC choke, first level,

harmonic filter as standard. If required,

additional harmonic filters and other

harmonic mitigation solutions, as

well as software tools for calculating

harmonic mitigation requirements are

also available.

Danfoss Drives has developed a wide

range of mitigation solutions which

can help restore weak networks,

increase network capacity, and meet

compact retrofit demands or secure

sensitive environments:

Advanced active filters

Advanced harmonic filters

Low harmonic drives

AFE low harmonic drives

12-pulse drives


Using reliable estimates of the harmonic impacts of AC drives, plants can avoid the hidden and often expensive consequences of harmonic interference: erratic performance or overloading of motors, circuit breakers and power factor correction devices.

The VLT® Motion Control Tool MCT 31 software enables a quick evaluation of whether additional harmonic mitigation is required. If so, the software can determine an optimal harmonic mitigation solution specifi c to the project to avoid unnecessary and costly over-engineering.

Easy to use at any phase of the mine projectThe VLT® Motion Control Tool MCT 31 software tool is easy to

use, requiring input of only a few points of readily available

data to get an initial assessment of the harmonic impact

on the mains supply. With more data entered, typically

available from electrical load lists and cable schedules even

at feasibility study stages of a mining project, the accuracy of

the results can be improved.

No need for high processing power The VLT® Motion Control Tool MCT 31 software tool provides

useful data without the need for the high processing power

requirements of more sophisticated harmonic calculation

tools. Although not a substitute for these sophisticated

alternatives, VLT® Motion Control Tool MCT 31 has proven

many times to provide a useable and reliable estimate of

the harmonic impact of AC drives at the different stages of

mining projects, from feasibility study through to detailed

engineering.

Harmonics calculation software

These Windows-based software tools provide easy

configuration via a PC, and provide plant managers

with a comprehensive overview of all the drives in a

system of any size. They add a new level of flexibility in

configuration, monitoring and troubleshooting.

VLT® Motion Control Tool MCT 10 is an

engineering tool enabling data exchange over a

traditional RS485 interface, fieldbus (PROFIBUS,

Ethernet, and more) or via USB. Use it with all VLT®

drives.

VACON® NCDrive is a commissioning tool

for the VACON® NXP drives, allowing for real

time parameterization and monitoring via the

standard RS-232 connection or optional CAN bus

option card.

The VACON® Live commissioning tool supports

the VACON® 100 Family of AC drive products.

Real-time parameterization and monitoring are

available via the standard RS-485 connection

using an RS-485 to USB converter or through the

built-in Ethernet port (AutoDHCP or Static IP).

Use of these software tools reduces the risk of incorrect

configuration, and facilitates rapid troubleshooting.

They are especially useful tools for documenting and

recording as-commissioned settings for each AC drive

on your site.

Easy engineering and setup with VLT® Motion Control Tool MCT 10, VACON® NCDrive and VACON® Live

Commissioning software


To enjoy the benefi ts of a single drive platform, with cost savings in training, service, and storage of spare parts:

■ Select a quality VLT® or VACON® drive meeting your specifi c requirements ■ Choose the best value, reliable and effi cient motor

for your system, enabled by Danfoss ‘one drive for all motors’ concept

Each VLT® or VACON® drive is confi gurable, compatible and effi ciency-optimized for all typical motors – liberating you from the performance and price restrictions of bundled motor-drive package deals.

Motor independence


Global service network – we react fast wherever you are

VLT® and VACON® drives operate on mine sites, stockyards, bulk materials handling facilities, processing plants and related port facilities all over the world.

No matter where or what your project, you can be sure Danfoss Drives will be there to back you up. You can get immediate access to our expertise through your local Danfoss offi ce, and you can call on service staff to minimize downtime and maximize productivity at your facility.

Our experts, located in more than 100 countries, are always ready to support you with engineering and application advice and service.

Our range of DrivePro® services provides you with the expert support, exactly where you need it, right on time. And we remain on the job until your drives challenges are solved.


DKDD.PB.423.A2.02 © Copyright Danfoss Drives | 2016.09

A better tomorrow is driven by drives

Danfoss Drives is a world leader in variable speed control of electric motors. We offer you unparalleled competitive edge through quality, application-optimized products and a comprehensive range of product lifecycle services.

You can rely on us to share your

goals. Striving for the best possible

performance in your applications is our

focus. We achieve this by providing the

innovative products and application

know-how required to optimize

efficiency, enhance usability, and

reduce complexity.

From supplying individual drive

components to planning and

delivering complete drive systems; our

experts are ready to support you all the

way.

You will find it easy to do business with

us. Online, and locally in more than

50 countries, our experts are never far

away, reacting fast when you need

them.

You gain the benefit of decades

of experience, since 1968. Our low

voltage and medium voltage AC drives

are used with all major motor brands

and technologies in power sizes from

small to large.

VACON® drives combine innovation

and high durability for the sustainable

industries of tomorrow.

For long lifetime, top performance, and

full-throttle process throughput, equip

your demanding process industries

and marine applications with VACON®

single or system drives.

Marine and Offshore

Oil and Gas

Metals

Mining and Minerals

Pulp and Paper

Energy

Elevators and Escalators

Chemical

Other heavy-duty industries

VLT® drives play a key role in rapid

urbanization through an uninterrupted

cold chain, fresh food supply,

building comfort, clean water and

environmental protection.

Outmaneuvering other precision

drives, they excel, with remarkable fit,

functionality and diverse connectivity.

Food and Beverage

Water and Wastewater

HVAC

Refrigeration

Material Handling

Textile

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robust, reliable ac drives for significant capex and opex...

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